Clamp ring for welded diaphragms

ABSTRACT

A diaphragm sealed flow cavity comprises a first body comprising a support surface, a diaphragm comprising an outer portion that is joined by a weld to the first body, a clamped portion, and an inner portion that is movable along an axis, with the clamped portion of the diaphragm being compressed between the bearing surface and the support surface. The diaphragm sealed flow cavity may include a cylindrical body having a crimped portion for joining the cylindrical body to the first body. The diaphragm sealed flow cavity may also include a member that applies a live load to the clamped portion of the diaphragm. In the exemplary embodiments, the diaphragm sealed flow cavity may be realized as part of a diaphragm flow control valve having a valve body, diaphragm and a housing.

RELATED APPLICATIONS

This application claims the benefit of pending U.S. provisional patentapplication Ser. No. 61/357,207 filed on Jun. 22, 2010, for CLAMP RINGFOR WELDED DIAPHRAGMS, the entire disclosure of which is fullyincorporated herein by reference.

TECHNICAL FIELD OF THE INVENTIONS

The present disclosure relates to diaphragm valves such as are commonlyused, for example, to contain, regulate or otherwise control flow ofliquid or gas fluids. More particularly, the disclosure relates todiaphragm valves of the type in which a portion of the diaphragm iswelded to a support surface.

BACKGROUND

Diaphragm valves are known and are used in many diverse applications forfluid flow control, including gas and liquid fluids. In one form, aportion of the diaphragm may be welded to a support surface in order toprovide a body seal that prevents loss of media to the environment.

SUMMARY OF THE DISCLOSURE

In accordance with an embodiment of one or more of the inventionspresented in this disclosure, a member is provided in a welded diaphragmvalve by which a compressive load is applied to a diaphragm near aregion where the diaphragm is welded to a support structure. Thiscompressive load functions to isolate the weld from bending stresses andmoments when the diaphragm is flexed or moved during valve actuation. Inone embodiment, the compressive load is a spring load or live loadproduced by an elastic deformation of the member to store potentialenergy that sustains an applied load on the diaphragm. In oneembodiment, the member comprises a clamp ring that is loaded by actionof a housing member. The housing member in one embodiment may comprise ahousing for an actuator used with the diaphragm valve. Others of theinventions include, separately or in various combinations: the clampring geometry or shape; the combination of a diaphragm valve, actuatorand clamp member; and a method for manufacturing a diaphragm valve.Different exemplary embodiments of the clamp ring or member aredisclosed herein, including integral and non-integral designs. Optionalembodiments may include a crimped housing, a knurled region between acrimped housing and valve body, and a visually perceptible base designthat indicates angular orientation of the valve body duringinstallation. An optional mounting bolt retention feature is alsoprovided, such as may be used, for example, with modular systems of thetype that have surface mount fluid components that can be disposed on asubstrate or other support surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an embodiment of a diaphragm valve and automatic actuatorassembly in elevation;

FIG. 2 is the assembly of FIG. 1 slightly rotated out of the plane ofthe drawing to illustrate a base configuration;

FIG. 3 is a longitudinal cross-section of the assembly of FIG. 1 withthe valve shown in an open position;

FIG. 4 is an enlarged view of a clamp ring portion of the assembly ofFIG. 3;

FIG. 4A is an enlarged view of the clamped diaphragm area of FIG. 4;

FIG. 4B is a perspective of a clamp ring embodiment;

FIG. 4C is a longitudinal cross-section of the clamp ring of FIG. 4B;

FIG. 5 is an embodiment of a diaphragm valve and manual actuatorassembly in perspective;

FIG. 6 is a longitudinal cross-section of the assembly of FIG. 5;

FIG. 6A illustrates an optional anti-rotation feature for the assemblyof FIG. 1;

FIG. 7 illustrates an alternative embodiment of a clamp ring;

FIG. 8 illustrates another alternative embodiment of a clamp ring;

FIG. 9 illustrates an alternative compression technique for a diaphragm;

FIG. 10 illustrates another embodiment of a clamp ring;

FIG. 11 illustrates another embodiment of a clamp ring centeringfeature;

FIG. 12 illustrates another embodiment of a clamp ring used in apneumatically actuated valve, in longitudinal cross-section;

FIG. 13 is an enlarged view of the clamp ring area of the assembly ofFIG. 12;

FIG. 13A is a perspective illustration of the clamp ring embodiment usedin FIG. 12;

FIG. 13B is an elevation in cross-section of the clamp ring embodimentof FIG. 13A taken along the line 13B-13B in FIG. 13A;

FIG. 14 illustrates a mounting bolt retention feature that mayoptionally be used with the assembly of the various embodiments hereinor other embodiments; and

FIGS. 14A-14C illustrate an exemplary method for using the retentionfeature of FIG. 14.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Although the exemplary embodiments herein are presented in the contextof a welded diaphragm valve that is manually or pneumatically actuated,such is not required. Other actuation techniques including but notlimited to solenoid and hydraulic actuation may be used. Also, theexemplary embodiments herein illustrate an integrated valve and actuatorassembly wherein the valve body may be used, for example, with surfacemounted manifold systems. But the inventions may be used with valvesthat do not have an actuator fully assembled therewith, and may be usedwith valves that are used in applications other than surface mountedmanifold systems. The inventions herein are directed to varioustechniques for increasing the cycle life for welded diaphragm valves,for example, for high pressure or high actuation rate or high ratedcycle applications, but the inventions may be used for valves thatoperate in less severe environments.

Moreover, the inventions are not limited to specific examples herein ofthe valve body design, porting, diaphragm design or actuator design, butrather the inventions may be used with many different types of weldeddiaphragm valves and actuators, and may also be used with other weldeddiaphragm devices such as regulators. Therefore, the inventions hereinare broadly applicable to devices that use a diaphragm to seal a flowcavity. The exemplary embodiments herein also illustrate use ofstainless steel diaphragms and assembly components, however, othersuitable materials may be used as needed for a particular application.The inventions may be used with single diaphragms or multiple stackeddiaphragms.

As used herein we refer to an automatic actuator to mean any actuatorthat does not use a manually actuated handle or other device that ismanually operable or coupled to or engaging the diaphragm to open andclose a valve. A manual valve refers to an actuator that uses a handleor other device that is manually turned or actuated by an operator.

Also as used herein, the terms “live load” and “spring load” andderivative forms of those terms refer to an elastic deformation of abody by which potential energy is stored in at least a portion of thebody so as to maintain a load applying force with another body. A liveload, for example, may be realized with a flexible or resilient memberthat acts in a spring-like manner to store potential energy as theresult of an elastic deformation of the member so as to maintain orsustain an applied load against another component. Such a member may inpractice be a spring, such as a Bellville spring, or function similar toa Bellville or other spring, but such is not required. Other suitablestructure may be used for the member to produce a live load effectwhether such alternative structure would be considered or classified asa spring. Although the elastic deformation is used for providing thelive load, there may or may not also be an accompanying plasticdeformation, meaning that the member need not exhibit just an elasticdeformation. A live load in the present disclosure is used to sustain aminimum load that compresses a portion of a diaphragm so as to maintainan isolation effect between a weld and flexure of the diaphragm as willbe further described below. The use of a live load contributes tomaintaining the desired compression of the diaphragm should there be arelaxation or slight separation of the compressing surfaces due tonormal operation of the diaphragm device, temperature, pressure,vibration and so on.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, devices and components, alternatives as toform, fit and function, and so on—may be described herein, suchdescriptions are not intended to be a complete or exhaustive list ofavailable alternative embodiments, whether presently known or laterdeveloped. Those skilled in the art may readily adopt one or more of theinventive aspects, concepts or features into additional embodiments anduses within the scope of the present inventions even if such embodimentsare not expressly disclosed herein. Additionally, even though somefeatures, concepts or aspects of the inventions may be described hereinas being a preferred arrangement or method, such description is notintended to suggest that such feature is required or necessary unlessexpressly so stated. Still further, exemplary or representative valuesand ranges may be included to assist in understanding the presentdisclosure, however, such values and ranges are not to be construed in alimiting sense and are intended to be critical values or ranges only ifso expressly stated. Moreover, while various aspects, features andconcepts may be expressly identified herein as being inventive orforming part of an invention, such identification is not intended to beexclusive, but rather there may be inventive aspects, concepts andfeatures that are fully described herein without being expresslyidentified as such or as part of a specific invention, the inventionsinstead being set forth in the appended claims. Descriptions ofexemplary methods or processes are not limited to inclusion of all stepsas being required in all cases, nor is the order that the steps arepresented to be construed as required or necessary unless expressly sostated.

With reference to FIGS. 1 and 2, a first embodiment of one or more ofthe inventions is presented in an automatic air actuated diaphragm flowcontrol valve assembly 10. For convenience, all references herein to“radial” and “axial” are referenced to the central longitudinal X axisand the radial axis Y except as may otherwise be noted. Also, allreferences herein to angles are referenced to the X axis except as mayotherwise be noted.

The valve assembly 10 includes a base 12 that may be used to mount theassembly to a support structure. For example, the valve assembly 10 maybe in the form of a surface mounted unit that can be installed on amodular platform such as a surface of a substrate or manifold for a gasstick (not shown). The base 12 may be integrally formed with the valvebody (FIG. 3) or separately joined thereto as needed. As such, the base12 may include mounting holes 14 that accept bolts use to secure thebase 12 to the support structure, as well as coplanar fluid ports 16, 18that may serve as inlet and outlet ports for fluid flow through thevalve assembly 10 as is well known. However, this exemplary applicationis but one of many, and the inventions herein are not limited to anyparticular application, use or installation design of the valve or theactuator or the porting arrangement.

The actuator and valve assembly 10 includes an actuator portion 20 and avalve portion 22, with the actuator portion 20 stacked on top of thevalve portion 22. A multi-piece cylindrical actuator housing 24 may bejoined to the valve portion 22 by a crimped portion 26 of the housing,however, other techniques may be used to join the actuator portion 20 tothe valve portion 22. Moreover, the housing 24 need not be multi-piecein all cases, or may have more or fewer sections as needed.

With reference to FIG. 3, many different types of actuators and actuatordesigns may be used as needed, including those known or later developed.In this example, a double piston air actuator 28 may be used, althoughsingle piston actuators may be used or more than two pistons may beused. The air actuator 28 is used to open and close a valve 30. Thevalve 30 may be realized in the form of a welded diaphragm valve havinga valve body 32 in which is formed a flow cavity 34 (in this embodimentbeing a flow control valve cavity) with first and second ports 36, 38that communicate respectively with the inlet and outlet ports 16, 18respectively (which port 16, 18 is the inlet and which is the outlet isa matter of design choice). An annular valve seat 40 surrounds the firstport 36. The valve seat 40 may optionally be a symmetrical seat so thatthe seat may be installed into the valve seat recess 41 (see FIG. 4A) ineither of two orientations to prevent the valve seat 40 from beinginstalled upside down. An all metal valve seat may alternatively beused, either as an integral or non-integral valve seat. In thisembodiment, the valve seat 40 may comprise a plastic such as PFA,Teflon™, or other suitable material that is compatible with the processfluid or media that will flow through the valve 30.

A disk-shaped diaphragm 42 overlays and seals the flow cavity 34 andincludes a radially inner portion 42 a that is deflected in a generallyaxial direction towards and away from the valve seat 40. When thediaphragm 42 is in a first position in which the inner portion 42 a ispressed into contact with the valve seat 40 by the actuator 28, thevalve 30 is closed, and when the diaphragm 42 moves to a second positionin which the inner portion 42 a is spaced from the valve seat 40, thevalve is open.

Movement of the diaphragm 42 between its first and second positions iscontrolled by the actuator 28. The actuator 28 may include a first orupper piston 44 and a second or lower piston 46. The upper piston 44 mayinclude a stem portion 44 a and a first air passage 43 that extendsaxially through the first piston 44 and is in fluid communication withan air chamber 45. The second piston 46 may include a first stem portion47 that is in operable contact or connection with a lower surface 44 bof the upper piston 44. The second piston 46 may further include asecond stem portion 48, also referred to herein as an actuator stem 48.The second piston 46 includes a second air passage 50 therethrough thatis in fluid communication with the first air passage 43. The second airpassage 50 may also include first and second cross-bores 50 a, 50 bwhich provide pressurized air to piston chambers 58, 60 respectively.Appropriate seals 51 such as o-rings for example, may be used to controlthe pressurized air inside the actuator 28.

The actuator stem 48 engages an optional drive button 52 that makescontact with an upper surface of the diaphragm 42, particularly in theinner portion 42 a of the diaphragm. An optional spring 54 may be usedto bias the pistons 44, 46 downward (as viewed in the drawings) so as toprovide a normally closed valve 30. A normally open valve configurationmay alternatively be used as needed. When the pistons 44, 46 are pusheddownward by the action of the spring 54, the button 52 presses downagainst the diaphragm 42 to force the diaphragm to its first or valveclosed position (not shown). In this first position, the first andsecond ports 36, 38 are not in fluid communication with each other. Inorder to open the valve 30, pressurized air is introduced into the airchamber 45 such as through an air fitting connection port 56.Pressurized air enters the piston chambers 58, 60 and forces the pistonsupward against the force of the spring 54. This movement of the pistonsaxially retracts the button 52 and the diaphragm 42 is able to move toits second or valve open position, which is the position illustrated inFIG. 3. In this second position the first and second ports 36, 38 are influid communication with each other. In lieu of the spring 54, theactuator 28 may be designed as a double acting actuator (not shown) inwhich air pressure is used to both open and close the valve 30, as iswell known in the art.

The diaphragm 42 may have many different shapes and configurations butwill generally have an outer perimeter that overlays and typicallyextends radially past the outer perimeter of the valve cavity 34. In theexemplary embodiments, the diaphragm 42 may be a domed diaphragm suchthat the inner portion 42 a has a curvature so that the diaphragm 42 isconcave on the fluid or wet side that faces the valve seat 40. Thiscurvature gives the diaphragm 42 a natural resilient bias outward andaway from the valve seat 40, so that when the pistons 44, 46 are axiallyretracted, the diaphragm 42 can pop or snap or otherwise move into itssecond or valve open position. Also, fluid pressure in the valve cavity34 will tend to force the diaphragm 42 toward the valve open positionwhen the pistons 44, 46 have been axially retracted. However, otherdiaphragm designs may be used including tied diaphragms in which thecentral portion of the diaphragm is joined to the actuator stem 48. Thusfar herein, the description of the actuator 28 and valve 30 design andoperation are well known and a matter of design choice.

With reference next to FIGS. 4 and 4A, we illustrate in greater detailsome of the inventive aspects of the present disclosure. The diaphragm42 at its radially outer peripheral portion or peripheral edge is joinedto the valve body 32 by a weld 62. The weld 62 may be formed by anysuitable technique including but not limited to electric arc, laserwelding, TIG and electron welding to name a few examples. This weld 62ensures a fluid tight joint or seal between the diaphragm 42 and thevalve body 32 so that fluid flow in the valve cavity 34 is restricted tobetween the first and second ports 36, 38 and also that process fluiddoes not enter into the actuator 28 or escape to the outsideenvironment. The weld site includes the actual weld 62 and a heataffected zone 64 of the diaphragm that may exhibit strength changes ascompared to the non-welded and non-heat affected portions of thediaphragm. The size and nature of the heat affected zone will depend inpart of the material of the diaphragm and the welding parameters used.

During valve actuation or operating cycles between valve open and closedpositions, the diaphragm 42 flexes substantially and may be exposed tohigh fluid pressures in the open position as well as to high cyclenumbers or cycle rates. The flexing diaphragm will tend to exert bendingmoments and stress at the weld 62 and also at the heat affected zone 64of the diaphragm. But with the concepts disclosed herein, we have beenable to achieve millions of cycles at rated pressures of about 145 psior more and burst pressures of about 4500 psi or more. The inventionsherein, however, may be used with valves that are not exposed to suchhigh fluid pressure or high cycle life.

With reference to FIGS. 4 and 4A, we provide a member or body 70 whichwe refer to herein as a clamp ring to describe its function of a bodythat is used to apply a compressive load between the diaphragm 42 andthe valve body 32 so as to isolate the weld 62 and optionally part orall of the heat affected zone 64 from the bending stresses and momentsof the diaphragm 42. The valve body 32 is provided with a supportsurface 72 which may be a planar annular shoulder or end face of theouter periphery of the valve body 32. The clamp ring 70 includes abearing surface 74 (also see FIG. 4C) positioned so as to apply acompressive load between a clamped portion 76 of the diaphragm 42 andthe valve body support surface 72. This compressive load compresses thediaphragm 42 against the support surface 72 at a location that isbetween the weld 62 and the inner portion 42 a of the diaphragm, andpreferably is radially inward and spaced from the weld 62 and alsopreferably radially inward and spaced from the heat affected zone 64. Itmay be in some designs that the clamped portion 76 will include aportion of the heat affected zone 64 of the diaphragm 42.

With reference also to FIGS. 4B and 4C, this embodiment of a clamp ring70 includes a generally annular radially outer body 80 with a circularouter wall 82. The circular outer wall 82 extends between first andsecond radially extending walls 84 and 86. Each radially extending wall84, 86 blends to an axially and radially projecting rib 88. Each rib 88extends to a bearing surface 74.

From each bearing surface 74, a concavely curved portion 90 blends to agenerally radially extending inner ring or disk 92. The inner ring 92extends to a central opening 94 at a radially inner edge 96. From eachbearing surface 74, a concavely curved portion 90 blends to a generallyradially extending inner ring or disk 92. The inner ring 92 extends to acentral opening 94 at a radially inner edge 96. With additionalreference to FIG. 4, it will be noted that the optional drive button 52is appropriately sized to partially extend through the central opening94 in the clamp ring 70. This allows the drive button 52 to engage thediaphragm central portion 42 a. In the exemplary embodiment, the outerdiameter of the drive button 52 is slightly less than the diameter ofthe central opening 94. Alternatively, the inner edge 96 of the centralopening may be used to retain the drive button 52 during handling. Forexample, the clamp ring 70 may retain the drive button 52 so that itdoes not drop out during subsequent assembly and handling of theactuator prior to assembly on the valve body 32. For example, the drivebutton 52 may include a flange (not shown) on its outside diameter thatengages the inside diameter of the clamp ring.

As viewed in the cross-section of FIG. 4C, the inner ring 92 mayoptionally symmetrically taper on both sides inwardly from the curvedportion 90 and forms a somewhat cantilevered extension from the outerbody 80. The inner ring 92 taper thus provides an inner portion 92 athat has a reduced width W as compared to the width of the inner ring 92closer to the ribs 88. This reduced width W provides a flexibility orelastic resilience to the inner ring 92 so that a load applied to ornear the inner portion 92 a will cause the clamp ring 70 to flex andelastically deform, particularly the inner ring 92.

As noted above, the actuator housing 24 may be a multi-piece housing,although alternatively may be a single piece housing. In any case, theactuator housing 24 includes a lower housing portion 24 a that may becrimped to the valve body 32 as at crimp 26 (FIG. 4). One of theinventive aspects of this disclosure are the advantages derived from theuse of a welded diaphragm. Diaphragm based flow control devices, such asdiaphragm valves for example, typically clamp down hard on the diaphragmperiphery between the valve body and another member such as a housing orbonnet. The housing may or may not also serve as the housing for anactuator. In any case, this clamping action is done in order to assure afluid-tight body seal about the outer peripheral portion of thediaphragm to seal the valve cavity. But the clamping is done with astatic load, meaning that the housing/bonnet and the valve bodytypically are bolted together and tightened down in order to apply ahigh compressive load on the diaphragm to form the body seal. The use ofbolts or screw or clamps to join a bonnet or housing to a valve body canresult in larger radial dimensions than desired. For example, assembliessuch as the exemplary assembly for surface mounted systems herein, theradial envelopes or footprint of the device can be quite constrained. Asa consequence, bolted assemblies that must fit within this envelope orfootprint can result in smaller diameter diaphragms which can reduceoverall flow rates.

We have discovered that by using a welded diaphragm and the optionalcrimped housing technique, we can provide a larger diameter diaphragm ina given size (footprint) device. This can be used to provide higherflow, for example. But we have also determined that with the weldeddesign used in high speed actuation and high cycle applications, thedesigner may want to isolate the weld from the bending stresses of thediaphragm. Therefore, the clamp ring may be used to provide thisisolation of the weld site from the bending stresses, with the clampring still fitting within the desired footprint. The live load aspectmay be used with a welded diaphragm regardless of the optional use of acrimped housing. When the optional crimping technique is used, it ispreferred that the clamp ring produce an active load against thediaphragm so as to maintain a body seal. This is because the crimpdesign may in some cases be susceptible to environmental effects andvibrations which could cause a loss in static load compression.Therefore, in the exemplary embodiment, the welded diaphragm, optionallive load and optional crimped assembly work together to provide adiaphragm flow control device that can have higher flow, lesssusceptibility to environmental effects and significantly higheroperating cycles, even into the millions of cycles without diaphragmfailure.

The lower housing 24 a is provided with an axially extending annularmember or protrusion 98 in the nature of a downwardly projecting flange(as viewed in the orientation of FIG. 4A). This protrusion 98 presents aload applying surface 100 that faces and contacts the inner ring 92 ofthe clamp ring 70 when the lower housing 24 a is joined to the valvebody 32. More particularly in this example the load applying surface 100engages the inner ring 92 near or at the inner portion 92 a or othersuitable position as needed. The protrusion 98 may be sized so that whenthe lower housing 24 a is joined to the valve body 32, the protrusion 98pushes downward against the inner ring 92 and deflects or elasticallydeforms the inner ring 92 downward due to the applied load from thelower cylinder 24 a as represented by the arrow F as viewed in FIG. 4C.

With reference again to FIG. 4A, the outer circumferential surface 82 ofthe clamp ring 70 may be closely received within the interiorcylindrical wall 102 of the lower housing 24 a. By having a small gap orclose fit between the outer wall 82 of the clamp ring 70 and theinterior cylindrical wall 102 of the actuator housing 24 a, the clampring 70 may be concentrically centered within the assembly 10 and alsomay be supported by the interior cylindrical wall 102 when theprotrusion 98 deflects the inner ring 92. This causes a clamping forceto be applied through the bearing surface 74 to clamp the diaphragm 42between the bearing surface 74 and the valve body support surface 72. Inthis manner, the load force of the lower housing 24 a against the innerring 92 is translated into a compressive live load or live loadedclamping force between the bearing surface 74 and the support surface 72to clamp and compress the outer clamped portion 74 of the diaphragmbetween the weld site (which may include the weld 62 and part or all ofthe heat affected zone 64) and the inner portion 42 a of the diaphragm.The load applying member in the form of the protrusion 98 thus applies aload against the inner ring 92 that is radially inward of the locationof the clamping force applied to the diaphragm 42. The clamping forcethat supports the diaphragm 42 helps isolate the weld 62 and a portionor all of the heat affected zone 64 of the diaphragm from bendingmoments and stress during movement of the diaphragm 42 as the valve isopen and closed. The clamped portion 74 also isolates stress and bendingmoments from affecting the weld 62 and a portion or all of the heataffected zone 64 when the valve 30 is in the open position under highpressure. Although not shown, a support member or backing member may beprovided on the non-wetted side of the diaphragm 42 in the gap 104 tosupport the diaphragm in the open position under pressure.

The live loading produced by the clamp ring 70 may be used to compensatefor changes in the various parts of the valve and actuator that couldreduce the clamping force between the diaphragm 42 and the valve body32. For example, the valve body 32 may comprises stainless steel whereasthe actuator housing 24 may comprise aluminum. These materials expandand contract at different rates due to different coefficients of thermalexpansion. When the assembly 10 is exposed to thermal changes, thecompressive load between the housing 24 and the valve body 32 maylessen, which could reduce the clamping force applied to the diaphragm42 in the clamped portion 74. By providing a live-loaded elasticdeformation of the clamp ring 70, the clamping force on the diaphragm 42may be maintained above a minimum designed value even though there maybe dimensional changes in the various components that are part of theassembly 10 during thermal variations that cause a reduction in theclamping force.

Note that in comparing FIG. 4A with FIG. 4C, in the latter the clampring 70 is in its free, unstressed state, whereas in the former theclamp ring 70 is shown installed and in its stressed state. Thus, theinner ring 92 in FIG. 4A has been elastically deflected somewhat(downwardly as viewed in FIG. 4A) due to the forces F applied to theinner ring 92 through the protrusion 98. This elastic deformation ordeflection acts in the nature of a spring to store potential energy thatis used to sustain a compressive load on the diaphragm at the clampedportion 74. The forces F applied to the cantilevered inner ring 92result in or translate to high forces F′ that apply a high compressivelive load to the diaphragm through the bearing surface 74.

The geometry of the clamp ring 70 facilitates the clamping action on thediaphragm, however, clamp rings with different shapes and geometries maybe used. To name a few alternative examples available, the outer wall 82need not be cylindrical but may have contours or other shapes such as aconvex shape. The first and second radially extending walls 84, 86 neednot lie on a radius but may taper in an axial direction. The ribs 88 mayhave a different profile and shape as well as the bearing surface 74.The inner ring 92 need not necessarily be tapered if sufficientflexibility is otherwise available.

From FIG. 4C it is to be noted that the clamp ring 70 is preferably,although not necessarily, symmetric about the X and Y axes. This allowsthe clamp ring 70 to be installed in either of two orientations alongthe X axis.

Although the protrusion 98 is illustrated as being integral with thelower housing 24 a, it may also be provided by a separate part installedin the assembly.

With reference to FIGS. 1 and 2 we illustrate another optional feature.The base 12 may typically include four sides 150 a-d and a flat lowersurface 152 and flat upper surface 154. Corners at intersecting sidesmay be selectively chamfered or otherwise visually marked so that anassembler can mount the valve body onto a surface in the correct angularorientation. For example, chamfered corners 156 may have a visuallysmaller chamfer length than chamfered corners 158. The smaller chamferedcorners 156 may be the two corners that are closest to one of the ports16, 18, for example the port 16 when used as an inlet, while the largerchamfer corners 158 may be closest to the other port 16, 18, for examplethe port 18 when used as an outlet. In this manner the assembler willknow the correct angular alignment of the base 12 without having to viewthe ports 16, 18 which also allows for post-assembly verification thatthe base 12 is properly oriented. The visually perceptible corners maybe used with any of the embodiments herein.

With reference to FIGS. 5 and 6 we illustrate an embodiment of amanually operated diaphragm valve assembly that incorporates one or moreof the inventions herein. The manual valve assembly 200 may include abase 202 that is integral with a valve body 204. The base 202 mayinclude mounting holes 206 as this embodiment is also for a surfacemount configuration. The valve body 204 includes two flow passages 208,210 that communicate with a valve cavity 212. A diaphragm 214 may bewelded to the valve body 204 at a weld 215 in a similar configuration tothe above embodiment of FIGS. 1-4.

A manually actuated handle 216 is used to rotate a threaded valve stem218 so as to move the diaphragm 214 between valve open and closedpositions. The valve stem 218 is threadably joined as at 219 to anoptionally single piece housing 220, and the handle 216 is secured tothe valve stem 218 by a bolt 222 so that rotation of the handle 216causes the valve stem 218 to be axially translated up and down dependingon the direction of rotation of the handle 216. The valve stem 218 mayengage a button 217 that contacts the non-wetted surface of thediaphragm 214. The valve stem 218 thus moves the diaphragm 214 betweenits open and closed positions by moving an inner portion towards andaway from the valve seat 224.

As in the above described embodiment herein, the housing 220 may bejoined to the valve body 204 by a crimped portion 226. With reference toFIG. 6A we illustrate an optional feature of providing a knurled portion205 of the valve body 204 below or adjacent to the crimped portion 226.This knurling or other suitable roughened or frictional interfacebetween the housing 220 and the valve body 204 will reduce any tendencyfor torque to be transmitted between the handle 216 and the valve body204, which torque could otherwise tend to weaken the crimped connectionor also adversely change the clamping force applied to the diaphragm.

A clamp ring 228 is provided and may be used in the same manner asdescribed in the above first embodiment. The handle 216 may be used as acap to enclose the actuator and valve assembly 200. The housing 220 mayinclude a load applying member 230 that engages the clamp ring 228 so asto impart a load on the inner ring 232 which is translated intocompressive live load to clamp the diaphragm 214 between the clamp ring228 and a support surface 234 on the valve body 204. The clamped portionof the diaphragm 214 preferably is spaced from and radially inward ofthe weld 215 and also preferably radially inward from a heat affectedzone of the diaphragm 214.

The manually actuated valve 200 in this example may be a quarter turnvalve, however other configuration may be used as needed including halfturn and full turn to name two examples. Because the valve stem 218 isthreadably joined to the housing 220 by the threaded connection 219,rotation of the valve stem 218 may have a tendency to impart unwantedtorque on the housing 220 which could weaken the crimped connectionbetween the housing 220 and the valve body 204. The clamp ring 228counteracts this tendency because in the area of the clamped portion ofthe diaphragm, there is substantial friction and load between theprotrusion 230 and the clamp ring 228, as well as substantial frictionand load between the clamp ring 228 and the welded diaphragm 214. Thesefrictional loads will tend to lessen and in many cases eliminate theeffect if any of torque induced in the housing 220 due to manualactuation of the valve 200.

In the first two embodiments above, the clamp ring as an integral singlepiece body provides both the clamping function on the diaphragm as wellas providing that load as a live load. However, in other embodiments,the clamping force and the live load may be accomplished with two ormore separate pieces. With reference to FIG. 7 we show such anembodiment in a diaphragm valve 250 having a welded diaphragm 252secured to the valve body 254 at a weld 256. The diaphragm 252 iscompressed between a clamp ring 258 and a support surface 260 of thevalve body 254. A separate live load member 262, for example, aBellville spring or other resilient spring-like member, is capturedbetween a support or load applying surface 264 of the housing 266 and abearing surface 268 of the clamp ring 258. The surface 264 mayalternatively be provided by a protrusion of the housing as in the firstand second embodiments described herein above. The member 262 in anunstressed or unloaded condition may have a conical or other non-planarshape that becomes somewhat or completely planar or possibly invertedwhen the housing 266 is secured to the valve body 254, thus providing alive load against the clamp ring 258. In an alternative embodiment, themember 262 or the housing 266 or both may be configured so that themember 262 cannot be installed backward or upside down as viewed in thedrawings.

In still another alternative embodiment illustrated in FIG. 8, the clampring 258 may also be welded to the valve body 254 as at weld 280 suchthat the clamp ring 258, diaphragm 252 and the valve body are joined byone or more welds. The clamp ring 258 is used to apply a clamping forceto the diaphragm against a non-welded support surface of the valve body254 radially inward of the weld site, and the live load member 262 isalso used to provide the live load bias against the clamp ring 258.

In the embodiment of FIG. 9 which is an alternative embodiment forexample to the embodiment of FIG. 4 or FIG. 6, a groove or other recess290 may be formed in the support surface 234 of the valve body 204. Atleast a portion of the clamped portion 76 of the diaphragm will bepressed down into this groove 290 when the clamp ring 70 is initiallyloaded, thereby providing a mechanical lock between the diaphragm 42 andthe valve body 32 and the clamp ring 70, which in some applications mayfurther help in isolating bending moments and stresses from affectingthe weld 62 or the heat affected zone 64.

In the embodiment of FIG. 10 we illustrate an alternative geometry forthe clamp ring 300. This clamp ring 300 may be an integral body or maybe realized, for example, with two Bellville type spring washerspositioned back to back (convex sides facing each other). In thisembodiment, the clamp ring 300 is captured between a surface 302 of thehousing and a support surface 304 of the valve body 306. The clamp ring300 includes a first load surface 308 that engages the surface 302 ofthe housing, and a bearing surface 310 that applies a compressive loadto the diaphragm 312. The double sided clamp ring 300 thus can providetwice the live load force to the diaphragm as compared with a singlesided embodiment such as FIG. 4. The protrusion of the housing (notshown) may still be used to further deflect the clamp ring as in theabove embodiments. Note that the compression of the upper side 316 ofthe clamp ring towards the lower side 314 also provides a live loadengagement.

In the embodiment of FIG. 11, the radially inner edge 320 of the clampring 322 may be tapered and the radius of the inner ring 324 sized sothat the inner edge 320 engages a tapered surface 326 of the protrusion328 of the actuator housing. This engagement may be used for centeringthe clamp ring 322 in the housing rather than having to necessarily relyon close tolerance control between the outside diameter of the clampring 322 and the inside diameter of the cylindrical interior wall 102 ofthe housing.

FIG. 12 illustrates another embodiment that may be similar in manyrespects to the embodiment of FIGS. 1-4 herein, and like referencenumerals are used for like parts and the description thereof need not berepeated. The difference in the two embodiments is the configuration andgeometry of the clamp ring 400. The clamp ring 400 may also be used inthe manual actuator embodiment of FIGS. 5 and 6, for example.

FIGS. 13, 13A and 13B illustrate the clamp ring 400 in greater detail.The clamp ring 400 includes an outer circumferential body 402 and aradially inwardly extending ring 404. The inner end 406 of the ring 404presents a surface 408 against which a load applying surface 100 of thehousing 24 a presses when the housing 24 a and valve body 32 areassembled. A rib 410 presents a bearing surface 74. The cantileverednature of the ring 404 flexes resiliently with an elastic deformation,and thereby translates the load provided by the housing 24 a into acompressive live-loaded force on the diaphragm 42, with a clampedportion 76 of the diaphragm being compressed between the bearing surface74 and the valve body support surface 72. This clamped portion 76 helpsisolate the weld site, particularly the weld 62 and a portion or all ofthe heat affected zone 64.

It will be noted that the embodiment of FIGS. 13A, B is not asymmetrical clamp ring about the X axis, although it may be configuredas symmetrical if so required. The clamp ring 400 presents a lowersupport surface 412 in close proximity to the non-wetted side of thediaphragm 42 so as to support the diaphragm 42 particularly when thediaphragm is stressed upwardly under fluid pressure when the valve isopen. Although asymmetrical about the radial axis Y, the clamp ring 400may be appropriately dimensioned so that if it is installed upside downin an orientation opposite that illustrated in FIG. 12, the heightprofile may not permit the housing 24 a from being installed on thevalve body 32.

With reference to FIG. 14 and FIGS. 14A-14C, an embodiment of anoptional mounting bolt retention feature is illustrated. This featuremay be used, for example, to retain mounting bolts 450 that are used toattach the base 12 to an adjacent manifold, substrate or other surface.Although illustrated in terms of a surface mount manifold device, theretention feature may be used in any application where it is desired toretain a mounting bolt with a body wherein the body can accommodate theretention feature.

The mounting bolts 450 are received in the mounting holes 14 (FIG. 2)and are used to attach the base 12 (including the valve and actuatorassembly) to a surface such as a manifold, substrate and so on. Aretention feature 452, in this example being realized in the form of anannular o-ring 452, is disposed on the housing 24 and sized with apreferably snug fit. In FIG. 14 the o-ring 452 has been pushed downclose enough to the base 12 so as to engage a surface 450 a of themounting bolts 450. The o-ring 452 should be selected to be ofsufficient width so as to prevent the mounting bolts 450 from fallingout of their respective mounting holes 14. The o-ring 452 thus preventsthe mounting bolts 450 from falling out of their respective mountingholes 14 during normal handling and transportation prior to mounting theassembly 10 onto a surface. As illustrated in FIG. 14A, in order toeither remove or insert one or more of the mounting bolts 450 into theirrespective mounting holes 14, the o-ring 452 may be rolled or slid upthe housing 24 to provide sufficient clearance to allow the mountingbolts to be inserted or removed. In FIG. 14B the o-ring 452 is slid backdown sufficiently to interfere with the mounting bolts 450 falling out.In FIG. 14C, once the assembly 10 has been mounted onto a surface (notshown) the o-ring 452 may be left in position or pulled up to adifferent position.

The inventions herein also contemplate methods associated with the,manufacture, operation and use of the clamp ring and other structuralfeatures of the diaphragm device. In one embodiment for example, amethod of manufacturing a diaphragm valve may include the steps ofwelding an outer portion of a diaphragm to a valve body and applying acompressive load to the diaphragm against the valve body at a clamplocation that is between the welded portion of the diaphragm and thecenter of the diaphragm. In a more specific embodiment, a live load isprovided for the compressive load. In a further embodiment, a method ofmanufacture may include the steps of welding an outer portion of adiaphragm to a valve body and crimping a housing about the diaphragm. Ina more specific embodiment, the crimped housing applies a load against amember that produces a live load compression on the diaphragm.

The inventive aspects have been described with reference to theexemplary embodiments. Modification and alterations will occur to othersupon a reading and understanding of this specification. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof.

We claim:
 1. A diaphragm valve, comprising: a first body comprising asupport surface and a valve seat, a diaphragm comprising an outerportion that is joined by a weld to said first body, a clamped portion,and an inner portion that is movable along an axis to contact said valveseat to close the diaphragm valve, a second body comprising an outerportion having a bearing surface and a flexible inner portion, saidclamped portion of said diaphragm being compressed between said bearingsurface and said support surface, said clamped portion of said diaphragmbeing disposed between said weld and said diaphragm inner portion, saidsecond body flexible inner portion being elastically deformed to apply aload between said bearing surface and said support surface.
 2. Thediaphragm valve of claim 1 wherein said diaphragm comprises a generallydisk shaped body having a peripheral edge, with said weld beingpositioned near or at said peripheral edge.
 3. The diaphragm valve ofclaim 1 wherein said clamped portion of said diaphragm isolates saidweld from bending stress when said diaphragm inner portion moves.
 4. Thediaphragm valve of claim 3 wherein said diaphragm inner portion isflexed between first and second positions to open and close thediaphragm valve.
 5. The diaphragm valve of claim 1 wherein said secondbody comprises a ring-like body having a radially outer portion and aradially inner disk that extends inward from said radially outer portionof said second the body, said radially outer portion of said second bodycomprising the bearing surface, said radially inner disk beingcantilevered from said outer portion of said second the body.
 6. Thediaphragm valve of claim 5 comprising a member, said member comprising aload applying surface that applies a load against said second bodyradially inner disk to compress said diaphragm clamped portion betweensaid bearing surface and said support surface.
 7. The diaphragm valve ofclaim 6 wherein friction between said first body and said member andfriction between said second body and said diaphragm resist relativerotation between said first body and said member.
 8. The diaphragm valveof claim 1 wherein said first body comprises a valve body and saidsecond body comprises a clamp ring.
 9. The diaphragm valve of claim 1wherein said clamped portion of said diaphragm is spaced from said weldand a heat affected zone of said diaphragm.
 10. The diaphragm valve ofclaim 1 wherein said clamped portion of said diaphragm is adjacent saidweld and a heat affected zone of said diaphragm.
 11. The diaphragm valveof claim 1 wherein said second body applies a spring load between saiddiaphragm and said first body support surface.
 12. The diaphragm valveof claim 1 comprising a cylindrical body joinable to said first body bya crimped portion of said cylindrical body.
 13. The diaphragm valve ofclaim 12 wherein said second body comprises a generally circular outerwall that closely fits within a cylindrical interior wall of saidcylindrical body to center said second body in said cylindrical body.14. The diaphragm valve of claim 12 wherein said cylindrical body atleast partially encloses an actuator.
 15. The diaphragm valve of claim 1wherein said second body comprises a symmetrical disk that issymmetrical about a radial axis of said second body.
 16. The diaphragmvalve of claim 1 wherein said second body comprises an integral bodythat applies said load against said diaphragm clamped portion as a liveload.
 17. The diaphragm valve of claim 1 wherein said second bodycomprises two separate parts, a first part that comprises said bearingsurface and a second part that produces a live load against saiddiaphragm clamped portion.
 18. The clamp ring of claim 1 wherein saidsecond body comprises a disk portion that comprises an elasticallydeformed and cantilevered ring.
 19. The clamp ring of claim 18 whereinsaid disk portion is asymmetrical about a radial axis of said clampring.
 20. A diaphragm valve having a longitudinal axis, comprising: avalve body comprising a support surface and a valve seat, a diaphragmcomprising an outer portion that is joined by a weld to said valve bodyand an inner portion that is movable along the longitudinal axis intocontact with said valve seat to close the diaphragm valve, a cylinderbody joined to the valve body, a clamp ring comprising a bearing surfacethat applies a compressive load against a clamped portion of saiddiaphragm and said valve body support surface, said clamp ringcomprising an elastically deformed portion that produces saidcompressive load against said clamped portion of said diaphragm, saidclamped portion of said diaphragm being disposed between said weld andsaid diaphragm inner portion.
 21. The diaphragm valve of claim 20wherein said diaphragm comprises a generally round body with a centerthat is coaxial with a longitudinal axis of the diaphragm valve, saidclamped portion of said diaphragm being radially inward from said weldand a heat affected zone of said diaphragm.
 22. The diaphragm valve ofclaim 20 wherein said cylinder body comprises a housing for an actuatorfor the diaphragm valve.
 23. The diaphragm valve of claim 20 whereinsaid cylinder body comprises a load applying surface that applies a loadagainst said clamp ring to produce said compressive load between saiddiaphragm clamped portion and said support surface of said valve body,said load applying surface applying load against said clamp ring at alocation that is radially inward of said clamped portion of saiddiaphragm.
 24. The diaphragm valve of claim 22 wherein said cylinderbody is joined to said valve body by a crimped portion of said cylinderbody.